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Apiwat Muttamara
Introduction
Modern Manufacturing
FMS, CIM
Jig
COUNTERSINK&BORE
Fixtures
Modular Fixtures
Assembly
Welding fixtures
Inspection
Mechanical-inspection fixtures
Optical-inspection fixtures
Electronic-inspection fixtures
Go - No go gage
Tool Design
Clamp
Locator
Support
Degrees of Freedom
Translational Rotational.
First Plane
TIPS
Use the largest surface of the part for the
first ("primary") reference plane.
Position the three support points as far
apart as possible.
If more than three support points are
required to prevent deflection, make the
additional points adjustable.
Second Plane
Third Plane
If more than one support point
is required to prevent
deflection, make the
additional points adjustable.
9 degrees fix
Positioning Locators
BASIC PRINCIPLES OF
LOCATING
To perform properly, workholders must
2. Part size
Number of locator used to reference a part
normally depends on the part size.
3-2-1 principle determines the minimum number
required
When holding force cannot be applied more than
six locators can be used
Less operator skill is required when placing the
workpiece in the holder
To Increase center line control
3. Stability
4. Cutting pressures
Try to place locator opposite of the tool
force to avoid deflection of the workpiece.
Where possible, tool-forces should be
such that they force the workpiece into
contact with the locators.
Holding forces should not be in the
opposite direction to the tool forces
6. Fool-proofing
Process of position locators such that part
will only fit in the proper position. Achieved
by foolproofing pin.
Chip removal
Controlling Chips
Sharp locators
Summary:
Clamping Rules of Thumb
Define three reference planes on the
workpiece and fixture.
Provide one opposing clamping force
opposite each plane to restrict movement.
When in doubt, rely on additional
cylinders to take up uncertainty.
C) Radail Location
Radial location
Supplement to the concentric locators to
provide a specified fixed relationship to the
concentric locator.
Combined location
Most workholders use a combination of
locational methods to completely locate a
workpiece.
1. External locators
Devices used to locate the part from
external surface.
Two basic forms of external locators are
fixed or adjustable.
Adjustable support
Threaded type adjustable supports
Internal locators
For locating holes and bored diameters
usually located internal surfaces.
Fixed locators machined to suit specific size
when the size variations are not large
example: base plate
Compensating locators: conical and self
adjusting
Integral locators
Locators which are machined into the
body of the work holder.
Disadvantage extra time for machining
and no replacement for wear or damaged
locators
Assembled locators
Similar to integral locators
Replaceable locators
V locators
Nests
FULL
Partial
Adjustable locators
Application: Workpiece surface is irregular; large
variations is the workpiece (Sand Castings)
Advantage: Cost is reduced as the location is
not critical
Relieved locators
To minimize contact between workpiece
and locators to avoid locator sticking and
jamming in the part.
.
Conical locators
Todays Agenda
Type of Locator
Trick of Design
Clamping Principle
Jig Design
Determining
Locator Size and
Tolerances
CLAMPING GUIDELINES
Clamping principles
B. CAM
A. Screw
D. Toggle Linkage
C. Wedge
E. Lever
2.Screw clamp
Hook Clamp
3. Cam clamp
Fast operating clamping devises
4. Toggle clamp
Fast clamping and release actions
Move completely clear of the workpiece
High ratio of holding force to actuation
force
Limited range of movement
Inability to compensate for different
thickness (suitable to only slight changes
of workpiece thickness)
A.
Definition
Jigs are work holders, which are designed to hold, locate, and support a workpiece
while guiding the cutting tool throughout its cutting cycle.
Drill jigs are drilling, tapping, reaming, countersinking, counter boring, chamfering,
and spot facing.
B.
Design considerations
1.
General, machine and process
General Consideration
Justification of manufacturing cost reduction
Machine Consideration
1. Size, Type, and Capabilities of machine
2. Machine should be capable of handling the part shape, size and accuracy
3. Enough space to mount Workholding device
4. Tool designer must know about table size, T slot size, machine travel axis
Jig Design
Process Consideration
a.
Template
b. Plate
c. Universal or pump
Universal jigs utilize a handle connected to a cam or rack and pinion to move either a busing plate or nest plate. Parts held in the universal jigs have surface adaptable
to fitting against the surfaces of the bushing plate and nest.
Leaf
Channel
Permit drilling in more than
one surface
Reduces number of setups
but increase in design and
manufacturing cost of jigs
tumble box
Indexing jigs
1. Placed on base and bore
2. Locating stud
3. Hex nut
4. C-Washer
5. Drill bushing
6. Index pin
7. Spring
8. Bushing plate
Used to drill hoes located in pattern.
Location for the holes is generally
taken from the first hole drilled.
54.1
2%